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Lincoln Electric SQUARE WAVE SVM118-A manual

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Table of contents for the manual

  • Page 1

    SERVICE MANUAL W orld’ s Leader in W elding and Cutting Pr oducts Premier Manufacturer of Industrial Motors Sales and Service through subsidiaries and Distributors W orldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. T el. (216) 481-8100 SVM118-A August, 1998 For use with machines having Code Numbers: 9951 9952 9953 9954 9955 SQU ARE[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i SQUARE W A VE TIG 355 W ARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN AW A Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For add[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii SQUARE W A VE TIG 355 WELDING SP ARKS can cause fire or explosion. 4.a. Remove fire hazards from the weld- ing area. If this is not possible, cover them to prevent the welding sparks from starting a fir e. Remember that welding sparks and hot materials [...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii SQUARE W A VE TIG 355 FOR ENGINE powered equipment. 7.a. T urn the engine off before tr oubleshooting and maintenance work unless the maintenance work requir es it to be running. 7.b. Operate engines in open, well-ventilated areas or vent the engine e[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv SQUARE W A VE TIG 355 PRÉCAUTIONS DE SÛRETÉ Pour votre pr opr e pr otection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales s[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v SQUARE W A VE TIG 355 Page Safety .................................................................................................................................................i-iv Installation ..........................................................................................................[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 SQUARE W A VE TIG 355 Installation T echnical Specifications Square W ave TIG 355 .........................................................................A-2 Input and Output Specifications .....[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 SQUARE W A VE TIG 355 TECHNICAL SPECIFICA TIONS - SQUARE W A VE TIG 355 INPUT - SINGLE PHASE ONL Y Input V oltages: 208 230 460 575 Input Currents @ 350A/3[...]

  • Page 9

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified personnel should install, use, or service this e[...]

  • Page 10

    3. Be sur e the torch and work cable rubber coverings are fr ee of cuts and cracks that allow high fre- quency leakage. Cables with high natural rubber content, such as Lincoln Stable-Arc ® better r esist high frequency leakage than neopr ene and other synthetic rubber insulated cables. 4. Keep the torch in good repair and all connections tight to[...]

  • Page 11

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-5 A-5 SQUARE W A VE TIG 355 FIGURE A.2 – INPUT SUPPL Y CONNECTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your sk[...]

  • Page 12

    The Square W ave TIG 355 should be permanently wired into the power system. Plugs or connectors ar e not recommended. INST ALLA TION A-6 A-6 SQUARE W A VE TIG 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE A.1 RECO[...]

  • Page 13

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT CONNECTIONS ELECTRIC SHOCK can kill. • Keep the electrode holder , TIG torch and cables insulation in good condition and in place. • Do not touch electrically live par[...]

  • Page 14

    DO NOT operate a water -cooled torch unless water is flowing. W ater doesn’t flow until the solenoid is actu- ated. If using a water -cooled torch with a Magnum water cooler , connect the cooler water outlet to the “W ater V alve In” fitting. Connect the TIG torch inlet to the “W ater V alve Out” fitting. If using a water -cooled torch wi[...]

  • Page 15

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ........................................................[...]

  • Page 16

    OPERA TION B-2 B-2 SQUARE W A VE TIG 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIO[...]

  • Page 17

    GENERAL DESCRIPTION The Square W ave TIG 355 is a constant current, single range square wave AC/DC TIG (GT AW) arc welding power source with built-in high fr equency stabilization. It also has stick (SMAW) capability . The Square W ave TIG 355 gives the operator full control of the welding current plus the ability to pr eset weld and start cur- ren[...]

  • Page 18

    • 115 V olt receptacle with 15 amp circuit br eaker . • 220 V olt European (Schuko) type receptacle with 2 amp circuit br eaker for water coolers (50/60Hz machines only). • Excellent arc starting and stability up thr ough 400 amps. • High resistance to AC arc r ectification. • No tungsten spitting within current range of elec- trode. • [...]

  • Page 19

    CONTROLS AND SETTINGS UPPER CASE FRONT CONTROLS Controls on the upper case fr ont control panel ar e used for manual TIG and stick welding. Their func- tions are described below . Some controls ar e active in both TIG and stick welding, while others are active in TIG only . Refer to Figure B.1 for contr ol locations. OPERA TION B-5 B-5 SQUARE W A V[...]

  • Page 20

    UPPER CASE FRONT CONTROL P ANEL The upper case front panel contr ols are used for man- ual TIG and stick welding. 1. CURRENT CONTROL SWITCH A two-position toggle switch: LOCAL (P ANEL): Current is contr olled by the machine settings; remote Amptr ol has no affect on current. REMOTE: Current is controlled by a r emote Amptrol up to the curr ent set [...]

  • Page 21

    6. PEAK CURRENT CONTROL Presets the maximum welding curr ent the machine will produce, fr om 2 through 400 amps. The preset curr ent is displayed on the digital ammeter when you are not welding. NOTE: The ammeter display is an indicator of the preset curr ent. Actual welding current will be slightly differ ent. If you use an Amptrol, it will contr [...]

  • Page 22

    At Maximum, the arc will be mor e for ceful and less prone to sticking but will pr oduce more spatter . 12. PREFLOW This control adjusts the amount of time the gas and water valves are open befor e the arc starts. It is adjustable from 0 to 10 seconds. The Preflow time occurs only if the valves wer e closed (no gas flow) when the Arc Start switch o[...]

  • Page 23

    Example: The Peak Current contr ol is preset at 50 amps and the Amptrol is partially down, giving a peak current of 30 amps. If the Backgr ound Current contr ol is set at 50%, the Background (low pulse) current will be 15 amps. The Amptrol raises and lowers the Peak curr ent. Since Background curr ent is always a percentage of Peak current, the Amp[...]

  • Page 24

    • ARC EST ABLISHED LED goes on when the arc is fully established and goes out if the arc goes out. • ST ART LED is on from the time the ar c is estab- lished until current begins to go up (soft start) or down (hot start). Note that the Start LED is off during upslope if a soft start is used. • PEAK LED goes on after the Start period. If the P[...]

  • Page 25

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-11 B-11 SQUARE W A VE TIG 355 LOWER CASE FRONT CONTROLS Refer to Figure B.3 for the location of the following contr ols. FIGURE B.3 – LOWER CASE FRONTCONTROLS 4 5 [...]

  • Page 26

    1. POWER ON/OFF — A momentary start/stop pushbutton, which controls the input contactor . If the input power supply goes off or if the thermo- stat in the welder trips, the start pushbutton must be pressed to r estart the welder . 2. PILOT LIGHT — Indicates when the input contac- tor is ener gized (power is on). Do not switch polarity under loa[...]

  • Page 27

    HAND AND FOOT AMPTROL OPERA TION Both the Hand and Foot Amptrol (optional kits K870 or K812) work in a similar manner . They are meant to be used for remote curr ent control when Remote Curr ent control is selected. The TIG 2-Step mode must be selected when using an Amptrol for r emote current control. As explained below , Amptrols can also be used[...]

  • Page 28

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-14 B-14 SQUARE W A VE TIG 355 FIGURE B.4 – AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION FIGURE B.5 – AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POS[...]

  • Page 29

    WELDING OPERA TION INITIAL ST ART -UP Be sure the Squar e W ave TIG 355 has been installed correctly with r espect to location, high frequency pr o- tection, input power , and output connections. If you are TIG welding, connect a K870 or K812 Amptrol or a K814 Ar c Start switch to the Remote Receptacle. Check that the gas supply is on. Check for th[...]

  • Page 30

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-16 B-16 SQUARE W A VE TIG 355 T ABLE B.1 SPECIFIC EFFECTS OF CONTROLS (illustrated in the 2-Step Mode for clarity) PRESET CURRENT LOCAL CURRENT CONTROL ALL LOWER P A[...]

  • Page 31

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-17 B-17 SQUARE W A VE TIG 355 PRESET CURRENT PRESET CURRENT CRA TER FILL % CURRENT MAX ST ART TIME LOCAL OR REMOTE CURRENT CONTROL ST ART SWITCH ON ST ART CURRENT SE[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-18 B-18 SQUARE W A VE TIG 355 PRESET CURRENT PRESET CURRENT CRA TER FILL % CURRENT BACKGROUND % CURRENT CLOSE ARC ST ART SWITCH OPEN ARC ST ART SWITCH AFTER SPOT TIM[...]

  • Page 33

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-19 B-19 SQUARE W A VE TIG 355 T ABLE B.2 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) DCEN (-) DCEP (+) T ungsten 1%, 2% 1%, 2% Electrode 1%, 2% 1%, 2% Tho[...]

  • Page 34

    TIG WELDING SEQUENCE OF OPERA TION (2-STEP MODE) Do not leave stick electrode welding cable connected. It will be electrically “hot” when TIG welding. 1. Connect an Amptrol or Ar c Start switch to the Remote Receptacle. 2. T ur n the welder , water supply (if equipped) and gas supply on. The pilot light on the front panel indicates when the pow[...]

  • Page 35

    11. Hold the Arc Start switch down until an ar c is established. At this point, the Arc Start Switch can be released, and the weld will continue. Press and r elease the Arc Start switch a second time to stop the arc. When the Afterflow timer completes the cycle, the gas and water valves close. T o make another weld, repeat steps 10 and 11. Note: St[...]

  • Page 36

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories..................................................................[...]

  • Page 37

    OPTIONS/ACCESSORIES The following options/accessories are available for your Square W ave TIG 355 from your local Lincoln Electric Distributor . Undercarriage (K841) – Includes a platform, wheels, and brackets for supporting the welder and two gas cylinders. Pump Mounting Platform (K827) – Mounts on top of the welder to provide a mounting surfa[...]

  • Page 38

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions.......................................................................[...]

  • Page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-2 D-2 SQUARE W A VE TIG 355 W ARNING SAFETY PRECAUTIONS • Only Qualified personnel should perform this maintenance. • T ur n the input power OFF at the disconne[...]

  • Page 40

    5. If any voltage is present, DISCHARGE EACH INDI- VIDUAL CAP ACITOR as follows: a. Obtain a 500 Ohm resistor . Grip the 500 ohm resistor with insulated gloves and insulated gripping pliers and hold the resistor acr oss the terminals on each capacitor for 20 seconds. See Figure D.1. b. With the volt/ohmmeter , recheck each capac- itor for voltage. [...]

  • Page 41

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-4 D-4 SQUARE W A VE TIG 355 FIGURE D.2 – GENERAL COMPONENT LOCA TIONS 1. OUTPUT RECTIFIER/SCR BRIDGE ASSEMBL Y 2. INPUT CONT ACTOR 3. RECONNECT P ANEL 4. PILOT TR[...]

  • Page 42

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation ............................................................................................................. Section E General Description .......................................................[...]

  • Page 43

    HIGH VOLTAGE  TRANSFORMER CIRCUIT REMOTE RECEPTACLE GAS/WATER SOLENOIDS FANS  115VAC RECEPTACLE    INPUT  CONTACTOR R E C O N N E C T POWER FACTOR CAPACITORS FEED - THRU BOARD CONTROL BOARD POWER   BOARD SNUBBER BOARD MAIN TRANSFORMER AC AC DC- DC+ POLARITY SWITCH SHUNT C H O K E  BY-PASS BOARDS  WORK ELECTRODE HI-FREQ[...]

  • Page 44

    OUTPUT RECTIFICA TION AND FEEDBACK CONTROL The AC output from the main transformer secondary is rectified and contr olled through the SCR bridge. Output current is sensed at the shunt as a low voltage signal and fed back to the control boar d. The control board compar es the commands of the control panels, panel switches, and/or remote contr ol wit[...]

  • Page 45

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-4 E-4 SQUARE W A VE TIG 355 HIGH VOL T AGE/ HIGH FREQUENCY CIRCUIT The control boar d signals the power boar d to pass the 115V AC voltage through the fee[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 SQUARE W A VE TIG 355 DC WELDING OUTPUT When the polarity switch is placed in either DC posi- tion, the AC voltage from the main transformer sec- on[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-6 E-6 SQUARE W A VE TIG 355 AC WELDING OUTPUT Rotating the polarity switch to the AC position changes the welding power circuit. One lead (X2) of the main[...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-7 E-7 SQUARE W A VE TIG 355 SCR OPERA TION A silicon controlled r ectifier (SCR) is a three-terminal device used to control rather lar ge currents to a lo[...]

  • Page 49

    PROTECTIVE CIRCUITS Protective cir cuits are designed into the Squar e Wave TIG 355 to sense trouble and shut down the machine before the tr ouble damages the internal machine com- ponents. Both thermal protection and curr ent over- load are included. THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures. Excessiv[...]

  • Page 50

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -TROUBLESHOOTING & REP AIR SECTION- T roubleshooting & Repair Section ....................................................................................... Section F How to Use T roubleshooting Guide .....................................[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-2 F-2 SQUARE W A VE TIG 355 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Pers[...]

  • Page 52

    ELECTRIC SHOCK can kill. Have an electrician install and ser- vice this equipment. T ur n the machine OFF befor e working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooti[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason yo[...]

  • Page 54

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason yo[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason yo[...]

  • Page 56

    TROUBLESHOOTING & REP AIR F-7 F-7 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshootin[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason yo[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason yo[...]

  • Page 59

    TROUBLESHOOTING & REP AIR F-10 F-10 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshoot[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-12 F-12 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 62

    TROUBLESHOOTING & REP AIR F-13 F-13 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for electrical troubleshoot[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT POWER F ACTOR CAP ACITOR VOL T AGE CHECK AND DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized rep[...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-21 F-21 INPUT POWER F ACTOR CAP ACITOR VOL T AGE CHECK AND DISCHARGE PROCEDURE (continued) TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input po[...]

  • Page 71

    ARC ST AR T TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safet[...]

  • Page 72

    F-23 F-23 ARC ST ART TRIGGER CIRCUIT TEST (continued) FIGURE F .2 – 6-PIN AMPHENOL RECEPT ACLE TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the screws and car efully lower the front control panel. 3. Locate plug J9 on the control PC boar d. ELECTRIC SHOCK can kill. ?[...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-24 F-24 ARC ST ART TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REP AIR FIGURE F .3 – ARC ST ART TRIGGER CIRCUIT 24VAC 3J16 1J16 5J18 8J23 5J2[...]

  • Page 74

    POWER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and prec[...]

  • Page 75

    F-26 F-26 POWER BOARD TEST (continued) FIGURE F .4 - POWER BOARD TEST POINTS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the screws and car efully lower the front control panel. 3. On the power board, locate the test points that are called out in the following Power B[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-27 F-27 POWER BOARD VOL T AGE TEST CHART TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 Check Points IJ4 to 2J4 4J4 to 6J4 4J4 to 5J4 10J4 to 12J4 3J2(+) to 5J2 4J2(-) to [...]

  • Page 77

    INPUT CONT ACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electri- cal shock, please observe all safety notes and[...]

  • Page 78

    F-29 F-29 INPUT CONT ACTOR TEST (continued) FIGURE F .5 - INPUT CONT ACTOR TEST POINTS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the machine top and sides. 3. Locate the two leads, #243 and #244, con- nected to the input contactor coil. See Figure F5. 4. Connect the[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-30 F-30 INPUT CONT ACTOR TEST (continued) TROUBLESHOOTING & REP AIR • If 120 VAC is pr esent when the Start button is held in but the contactor does[...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-31 F-31 TROUBLESHOOTING & REP AIR INPUT CONT ACTOR TEST (continued) FIGURE F .6 - INPUT CONT ACTOR (CR1) SIMPLIFIED CONTROL CIRCUIT X1 X2 T2 PILOT TRA[...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 PILOT TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equ[...]

  • Page 82

    F-33 F-33 PILOT TRANSFORMER TEST (continued) FIGURE F .7 - PILOT TRANSFORMER CONNECTIONS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the machine top and sides. 3. Locate terminals X1 and X2 connected to the pilot transformer secondary . See Figure F .7. 4. Connect the[...]

  • Page 83

    FEED-THRU PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes a[...]

  • Page 84

    F-35 F-35 FEED-THRU PC BOARD TEST (continued FIGURE F .8 - FEED-THRU PC BOARD LOCA TION TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the machine top and sides. 3. Perform the power factor capacitor dis- char ge procedure. 4. Remove plugs J15, J16, J17, and J18 fr om th[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-36 F-36 FEED-THRU PC BOARD TEST (continued ) TROUBLESHOOTING & REP AIR FIGURE F .9 - FEED-THRU PC BOARD PLUG DET AILS – PLUGS J15 AND J16 FIGURE F .[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-37 F-37 FEED-THRU PC BOARD TEST (continued ) FEED THRU PC BOARD RESIST ANCE TEST POINTS TROUBLESHOOTING & REP AIR Check Points 5J15 to 7J17 4J15 to 6J17 6J15 to 10J17 7J15 [...]

  • Page 87

    PROTECTION PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes [...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-39 F-39 PROTECTION PC BOARD TEST (continued) FIGURE F .11- PROTECTION PC BOARD LOCA TION AND MOUNTING DET AILS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input powe[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-40 F-40 PROTECTION PC BOARD TEST (continued) PROTECTION PC BOARD RESIST ANCE TEST POINTS CHART TROUBLESHOOTING & REP AIR T est Points 1J22 to 3J23 2J2[...]

  • Page 90

    MAIN TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and[...]

  • Page 91

    F-42 F-42 MAIN TRANSFORMER TEST (continued) FIGURE F .12 - MAIN TRANSFORMER LOCA TION AND WIRING DET AILS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the machine top and sides. 3. Perform the power factor capacitor dis- char ge procedure. 4. Inspect the input contacto[...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE W A VE TIG 355 F-43 F-43 MAIN TRANSFORMER TEST (continued) TROUBLESHOOTING & REP AIR 7. Check the voltages at the test points listed on the Main T ransformer V oltage [...]

  • Page 93

    CONTROL TRANSFORMER (T5) VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe al[...]

  • Page 94

    F-45 F-45 CONTROL TRANSFORMER (T5) VOL T AGE TEST (continued) FIGURE F .13 - LOCA TION OF CONTROL BOARD AND CONTROL TRANSFORMER TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver , remove the machine case top and sides. 3. Locate plug J4 on the power board. (Do not remove.) Also locate [...]

  • Page 95

    F-46 F-46 CONTROL TRANSFORMER (T5) VOL T AGE TEST (continued) FIGURE F .14 – PLUG P4 DET AILS TROUBLESHOOTING & REP AIR 6. Check fuse F1 (0.5 amp). T est the resis- tance from 6J15, on the feed-thru PC board, to the #265 lead at the contr ol trans- former . Also check the resistance fr om 7J15, on the feed-thru PC board, to the #266 lead at t[...]

  • Page 96

    CONTROL PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and[...]

  • Page 97

    F-48 F-48 CONTROL PC BOARD TEST (continued) FIGURE F .15 – CONTROL PC BOARD LOCA TION TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver , remove the screws and car efully lower the case front control panel. 3. Locate the test points on the control PC board that ar e called out in the[...]

  • Page 98

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-49 F-49 CONTROL PC BOARD TEST (continued) FIGURE F .16 – CONTROL PC BOARD PLUG DET AILS PLUG J13 LOCA TION RESISTOR TEST POINTS (Control Boar d Area Enlarged) TROUBLESHOOTING[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-50 F-50 CONTROL PC BOARD TEST (continued) CONTROL PC BOARD VOL T AGE TEST POINTS CHART TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 Special Signals Being Expected Condit[...]

  • Page 100

    ST A TIC SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and pre[...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-52 F-52 ST A TIC SCR TEST (continued) FIGURE F .17 – POWER PC BOARD PLUG LOCA TIONS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove the input power to the machine. 2. [...]

  • Page 102

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-53 F-53 ST A TIC SCR TEST (continued) FIGURE F .18 – SCR TEST POINTS TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 SCR 3 & 4 Anode and Negative Plate #4 Cathode #1 [...]

  • Page 103

    ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and preca[...]

  • Page 104

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-55 F-55 ACTIVE SCR TEST (continued) FIGURE F .19 - POWER BOARD PLUG LOCA TIONS TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Remove the input power to the machine. 2. With th[...]

  • Page 105

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-56 F-56 ACTIVE SCR TEST (continued) FIGURE F .20 – SCR TEST POINTS TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 SCR 3 & 4 Anode and Negative Plate #4 Cathode #1 An[...]

  • Page 106

    F-57 F-57 ACTIVE SCR TEST (continued) FIGURE F .21 - SILICON CONTROLLED RECTIFIER TEST SETUP . TROUBLESHOOTING & REP AIR SILICON CONTROLLED RECTIFIER TEST (Heat Sink Mounted Units) T o test the SCRs, construct the circuit outlined in Figure F .21. One 6V lanter n battery can be used. Resistor tolerances are 10%. The volt- meter scale should be [...]

  • Page 107

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-58 F-58 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 108

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-59 F-59 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 109

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-60 F-60 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 110

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-61 F-61 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 111

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-62 F-62 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 20 volts SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 112

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-63 F-63 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 20 volts SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 113

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-64 F-64 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 114

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-65 F-65 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....2 ms/Div . C[...]

  • Page 115

    CONTROL PC BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe [...]

  • Page 116

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-67 F-67 CONTROL PC BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .22 - CONTROL PC BOARD TROUBLESHOOTING & REP AIR TEST PROCEDURE Before starting the following pr oced[...]

  • Page 117

    POWER PC BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe al[...]

  • Page 118

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-69 F-69 POWER PC BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .23 - POWER PC BOARD TROUBLESHOOTING & REP AIR PROCEDURE Before starting the following pr ocedure, refe[...]

  • Page 119

    INPUT CONT ACTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe [...]

  • Page 120

    F-71 F-71 INPUT CONT ACTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .24 – INPUT CONT ACTOR CONNECTIONS TROUBLESHOOTING & REP AIR PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver , remove the case top and sides. 3. Perform the Input Power Factor Capacitor V oltage Check. 4. With the 5/16" nut driver ,[...]

  • Page 121

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-72 F-72 INPUT CONT ACTOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 13. Replacement: Mount the contactor brack- et assembly to the case back and attach [...]

  • Page 122

    F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obse[...]

  • Page 123

    F-74 F-74 F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT (continued) FIGURE F .25- F AN MOTOR AND BLADE MOUNTING DET AILS TROUBLESHOOTING & REP AIR PROCEDURE The following procedur e allows you to remove and replace either of the two fans on the Square W ave TIG 355. 1. Remove the input power to the machine. 2. With the 5/16" nut driver , r[...]

  • Page 124

    OUTPUT RECTIFIER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe [...]

  • Page 125

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-76 F-76 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) FIGURE F .26 – OUTPUT RECTIFIER CONNECTION DET AILS Step 13 [...]

  • Page 126

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-77 F-77 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the machine. 2. With the 5/[...]

  • Page 127

    SCR REMOV AL AND AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safet[...]

  • Page 128

    F-79 F-79 SCR REMOV AL AND AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR The unclamping and clamping procedur e out- lined below is critical for the prevention of iner- nal SCR damage. Failure to follow this pr oce- dure may r esult in subsequent damage of the SCR. Handle all SCRs with care. PROCEDURE 1. Perform the Output Rectifier Rem[...]

  • Page 129

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-80 F-80 SCR REMOV AL AND AND REPLACEMENT (continued) TROUBLESHOOTING & REP AIR 8. Place the new SCR betwen the heat sinks. Be sure that the outer metal ring of the SCR is f[...]

  • Page 130

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-81 F-81 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 5) Re-inspect the SCR for proper seating. 6) Clamp the cap screws. Use the procedur e for 1/4-28 cap screws or 1/4-2[...]

  • Page 131

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-82 F-82 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 B. PROCEDURE FOR THE 5/8 INCH WIDE SPRING: 1) Place a piece of sleeving around each cap screw . 2) Insert the cap sc[...]

  • Page 132

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-83 F-83 TROUBLESHOOTING & REP AIR SQUARE W A VE TIG 355 Clamping procedur e for 1/4-20 cap screws. Note: This pr ocedure can only be used with 1/4-20 cap screws. Do not use[...]

  • Page 133

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any r eason that requires you to r emove any mechanical part which could affect the machine’ s elect[...]

  • Page 134

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-85 F-85 SQUARE W A VE TIG 355 RETEST AFTER REP AIR (continued) OUTPUT CURRENT RANGE 2 - 400 Amps AC and DC RECOMMENDED METERS FOR MACHINE OUTPUT T[...]

  • Page 135

    T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - SQUARE W A VE TIG 355 Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Machine Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 136

    NOTES SQUARE W A VE TIG 355 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 137

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-2 SQUARE W AVE TIG 355 Wiring Diagram DUAL VOLTAGE MACHINE SINGLE VOLTAGE MACHINE MODE S10 LOCAL STICK CONTINUOUS REMOTE TIG OFF S11 S12 START TO GROUND PE[...]

  • Page 138

    NOTE: This diagram is for reference only . It may not be totally applicable to every code covered by this manual. G-3 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Machine Schematic SHUNT (+) SHUNT (-) BACKGROUND RECTIFIER (+) PRIMARY THERMOSTAT PRIMARY THERMOSTAT BACKGROUND RECTIFIER (-) BACKGROUND RESISTOR SCR1 GATE SCR2 GATE SCR3 GATE SCR4 GATE B.G. [...]

  • Page 139

    G-4 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Meter PC Board (M15893) Schematic +5V R9 X5 3 4 H Q A C Q Q CLK Q Q Q B Q A1 A2 E F G Q R D 74HC164 X1 6 4 2 12 13 1 10 11 8 5 3 9 X5 11 10 C7 J7 3 3.01K R28 R25 50V 330p C5 C3 C2 74HC164 X3 14 7 X5 13 12 50V 330p C6 J7 2 J7 1 J7 4 R26 54HC74 X4 7 14 X5 1 2 C4 HEXINV X5 14 7 74HC164 X2 14 7 X5 98 R7 C8 L[...]

  • Page 140

    G-5 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Feed Through PC Board (L8096) Schematic J15 5 J17 9 3000V C4 .0047 J17 8 C5 .0047 3000V J17 7 J15 6 J15 4 .39mH 1A L4 J15 10 3000V C1 .0047 .39mH L2 J15 2 J17 4 3000V C20 .0047 C2 .0047 3000V J17 6 .39mH 1A L6 3000V C3 .0047 C6 .0047 3000V .39mH L1 .39mH 1A L5 J15 7 J17 10 .39mH 1A L7 3000V C19 .0047 C9 [...]

  • Page 141

    G-6 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Protection PC Board (M16062) Schematic SUPPLY VOLTAGE NET FRAME CONNECTION COMMON CONNECTION 3000V .0047 C4 J23 1 J23 4 EARTH GROUND CONNECTION POWER SUPPLY SOURCE POINT NOTES : WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CO[...]

  • Page 142

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-7 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Power PC Board (G2081) Schematic G-7 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level tr[...]

  • Page 143

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-8 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Control PC Board (G2512) Schematic G-8 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level [...]

  • Page 144

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Protection PC Board (M16062) Layout G-9 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level[...]

  • Page 145

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-10 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Power PC Board (G2081) Layout G-10 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level tro[...]

  • Page 146

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-11 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Bypass PC Board (M15299) Layout G-11 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level t[...]

  • Page 147

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-12 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Feed Through PC Board (L9096) Layout G-12 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board le[...]

  • Page 148

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-13 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Control PC Board (G2512) Layout G-13 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level t[...]

  • Page 149

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-14 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 355 Meter PC Board (M15893) Layout G-14 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level tr[...]